Automated system and method for lumber analysis

ABSTRACT

A system that includes a computer processor having a plurality of input data devices, a plurality of output data devices, and a plurality of sensors; and a mechanical assembly integrated with the computer processor to reposition a piece of wood lumber based on software code executing in the computer processor. In some embodiments, the system performs a method that includes eliciting and receiving into the computer processor data parameters from a first human user; obtaining incoming data points about the lumber from the plurality of sensors; processing and storing the data parameters; comparing the incoming data points to the data parameters to obtain comparison results; and, based on the comparison results, (1) rejecting the lumber to a preprogrammed position, (2) feeding the lumber into a saw assembly as positioned, or (3) repositioning the lumber to a more optimal position prior to feeding the lumber to the saw assembly.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority benefit, under 35 U.S.C. § 119(e), ofU.S. Provisional Patent Application No. 62/388,048, filed Jan. 14, 2016by Steven Weinschenk, titled “AUTOMATED SYSTEM AND METHOD TO ENHANCESAFETY AND STRENGTH OF WOOD TRUSS STRUCTURES,” which is incorporatedherein by reference in its entirety.

This invention is related to:

-   -   U.S. Provisional Patent Application 62/144,859 filed Apr. 8,        2015 by Steven Weinschenk, titled “DIGITAL PROJECTION SYSTEM AND        METHOD FOR WORKPIECE ASSEMBLY”;    -   U.S. patent application Ser. No. 15/093,732 filed Apr. 7, 2016        by Steven R. Weinschenk et al., titled “DIGITAL PROJECTION        SYSTEM AND METHOD FOR WORKPIECE ASSEMBLY” (which issued as U.S.        Pat. No. 10,210,607 on Feb. 19, 2019); which are both        incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates to devices and methods to workpieceassembly, and in particular to automated systems and methods for lumberanalysis, sorting, adjustment, and sawing for workpiece assembly, suchas the assembly of wooden roof trusses, pre-assembled walls, and thelike. Some embodiments organize each incoming stack of lumber in one ofa plurality of vertically spaced apart bunks, one on top of another, andprovide a gantry that picks a selected board from the stack of lumber ona selected bunk, and moves the board in a direction generally parallelto the long axis of the board from the bunk to one of a plurality ofprocessing stations, wherein the plurality of processing stationsincludes a flipping station and/or a sawing station.

BACKGROUND OF THE INVENTION

One problem with today's conventional technology is that, when manuallyloading wood into the infeed systems, the human operator needs todetermine how to orient the wood, which increases the cost of labor whenmanufacturing structures using wood boards (lumber). As used herein,“crook” is a lumber feature or defect where the widest faces of thepiece of lumber are substantially planar but there is a curvature alongthe length of the narrower faces of the piece of lumber. The “crown” isthe convex one of the narrower faces of the piece of lumber with acrook. The crown should be orientated to optimize with the wood sawequipment. Certain wood trusses and pre-assembled walls are more secureif the crown of the wood is oriented correctly (both when the board isloaded into a sawing station, and when the cut board is assembled into atruss, a pre-assembled wall, or the like). Conventional automated orpartially automated systems are unable to determine and/or distinguishthe crown of the lumber.

U.S. Pat. No. 6,170,163 to Robert A. Bordignon et al. titled “METHOD OFASSEMBLING COMPONENTS OF AN ASSEMBLY USING A LASER IMAGE SYSTEM,” issuedJan. 9, 2001, and is incorporated herein by reference. In U.S. Pat. No.6,170,163 Bordignon et al. describe a method of assembling components ofan assembly, such as the components of a truss, using a laser imagingsystem in combination with assembly jigs. The jigs may be slidablymounted on an assembly table wherein the jigs include laser alignmentindicia on a top surface of the jigs spaced a predetermined distancefrom a side surface of the jigs. The method includes projecting anenlarged laser generated outline of at least a portion of the componentsto be assembled which is spaced laterally from an outline or template ofthe components in the assembled position a distance equal to thedistance between the laser alignment indicia and the side surface of thejigs and spaced vertically a distance equal to the distance between theindicia and the work surface. The jigs are then moved on the worksurface to align the laser alignment indicia with the enlarged outlineand affixed relative to the work surface. Finally, the components areassembled on the work surface in generally abutting relation with theside surfaces of the jigs and assembled. Where the assembly method ofthis invention is used for assembling trusses, the laser generatedoutline may be used to orient the truss planks.

U.S. Pat. No. 7,463,368 to Jarrad V. Morden et al. titled “LASERPROJECTION SYSTEM, INTELLIGENT DATA CORRECTION SYSTEM AND METHOD,”issued Dec. 9, 2008, and is incorporated herein by reference. In U.S.Pat. No. 7,463,368 Morden et al. describe a laser projection system,intelligent data correction system and method which corrects fordifferences between the as-built condition and the as-designed conditionof a workpiece which includes determining the as-built condition of aworkpiece with a digitizer scanner and modifying data of the as-builtcondition or the data of a laser projection based upon the data receivedfrom the digitizer scanner of the as-built condition. A preferredintelligent data correction system includes metrology receivers fixedrelative to the digitizer scanner and the workpiece and a metrologytransmitter to determine the precise location and orientation of thedigitizer scanner relative to the workpiece.

U.S. Pat. No. 7,621,053 to Edward S. Bianchin titled “ASSEMBLYAPPARATUS,” issued Nov. 24, 2009, and is incorporated herein byreference. In U.S. Pat. No. 7,621,053 Bianchin describes an assemblyapparatus for assembling components including a work surface, a laserprojector, a computer controlling the laser projector to protect a laserimage on the work surface, and an ejector lifting a completed assemblyfrom the work surface having a retro-reflective surface within a fieldof view of the laser projector when the ejector is lifted, such that thelaser projector scans the retro-reflective surface and the computerdetermines at least one of the number of completed assemblies made andthe time required to make the assembly.

United States Patent Publication 2010/0201702 of Franik et al. publishedAug. 12, 2010 with the title “DIGITAL IMAGE PROJECTION LUMINAIRESYSTEMS,” and is incorporated herein by reference. In Patent Publication2010/0201702 Franik et al. describe improvements to digital imagineprojection systems and for seamless blending of images projected from aplurality of digital image projectors to create combined images frommultiple projectors where the user is provided with independent controlof the blend area and of independent control of image parameters withinsaid variable blend area such as brightness, contrast, individual colorintensity and gamma correction.

U.S. Pat. No. 8,079,579 to Fredrickson et al. titled “Automatic trussjig setting system,” issued Dec. 20, 2011, and is incorporated herein byreference. In U.S. Pat. No. 8,079,579 Fredrickson et al. describe anautomatic truss jig setting system that includes a table including aplurality of segments with a side edge of adjacent segments defining aslot. At least one pin assembly, and optionally a pair of pinassemblies, is movable independently of each other along the slot.Movement apparatus is provided for independently moving the pinassemblies along the slot. Each of the side edges of the segmentsassociated with the slot defines a substantially vertical plane with azone being defined between the substantially vertical planes of the sideedges, and the movement apparatus is located substantially outside ofthe zone of the slot. The invention may optionally include a system forhandling the obstruction of pin assembly movement, and a system forkeeping track of the position of the pin assembly when the pin assemblyhas encountered an obstruction.

U.S. Pat. No. 8,782,878 to Jarrad V. Morden et al., titled “FASTENERAUTOMATION SYSTEM,” issued Jul. 22, 2014, and is incorporated herein byreference. In U.S. Pat. No. 8,782,878, Morden et al. describe a fastenerautomation system for assembly of fasteners to a substrate, whichincludes a projection system for projecting an image on a substrate of apredetermined location of a correct fastener to be installed in thesubstrate and data relating to the correct fastener and the substrate,and a computer operably associated with the projection system storingdata regarding the correct fastener and the predetermined location onthe substrate where the correct fastener is to be installed. Anautomated method of installing a fastener in a substrate at apredetermined location includes using a projector system to identify apredetermined location for installation of a correct fastener to thesubstrate, collecting data regarding the correct fastener installationat the predetermined location and storing the data in a computer, andinstalling the correct fastener in the substrate at the predeterminedlocation based upon the data.

United States Patent Publication 2008/0297740 of Huynh et al. publishedDec. 4, 2008 with the title “Projection system and method of usethereof,” and is incorporated herein by reference. In Patent Publication2008/0297740 Huynh et al. describe a projection system and method of usethereof, wherein a computer in electrical communication with at leastone projector projects a layout, preferably onto a floor projectionsurface utilizing short throw lenses, wherein the layout preferablycomprises a grid and indicia relating to an exhibitor.

U.S. Pat. No. 8,919,001 to Le Mer et al. titled “METHOD AND SYSTEM FORHELPING TO POSITION A COMPONENT ON A STRUCTURAL ELEMENT,” issued Dec.30, 2014, and is incorporated herein by reference. In U.S. Pat. No.8,919,001 Le Mer et al. describe a method for helping to position acomponent on the wall of a structural element, including the steps:elaborating an image to be projected on the wall, from a virtual modelof the structure and from the positioning of a projector with respect tothe structure, and an additional motif providing positioning informationof the piece with respect to the direction normal to the wall,projecting the image on the structural element by means of theprojector; placing the base of the piece inside an outline of the imageprojected on the wall; and, while keeping contact between the piece andthe structural element, modifying the positioning of the piece withrespect to the direction normal to the wall, until the predefined set ofpoints of the piece coincides with the motif.

U.S. Pat. No. 8,960,244 to Aylsworth et al. titled “AUTOMATED LUMBERRETRIEVAL AND DELIVERY,” issued Feb. 24, 2015, and is incorporatedherein by reference. In U.S. Pat. No. 8,960,244 Aylsworth et al.describe an automated lumber handling system that laser-scans the topprofile of multiple stacks of lumber, each of which contain boards of aunique size. Based on the scanned profiles, the system determines theorder in which individual boards from a chosen stack should betransferred to a numerically controlled saw. The saw cuts the boards toproper size, and in the proper sequence to facilitate orderly assemblyof a roof truss or prefabricated wall. In some examples, the systemlifts individual boards by driving two retractable screws, or some otherpiercing tool, down into the upward facing surface of the board. A trackmounted cantilever, holding the screws and a laser unit, translates overthe lumber stacks to retrieve and deliver individual boards and, whiledoing so, the laser repeatedly scans the stacked lumber profileson-the-fly to continuously update the profiles. The open cantileverdesign facilitates replenishing the stacks of lumber.

Chinese Patent Publication CN 202899636 U published Apr. 24, 2013 withthe title “Discrete assembly device for large-span rectangular spatiallywarped tube truss,” and is incorporated herein by reference. ThisChinese Patent Publication CN 202899636 describes a discrete assemblydevice for a large-span rectangular spatially warped tube truss. Thedevice consists of a base, two supporting tubes fixedly connected to thetwo sides of the base, and tube brackets fixedly connected to the topsof the supporting tubes, wherein grooves of which the diameter ismatched with that of a lower chord of an assembly section truss areformed on the tube brackets. The on-site assembly difficulty of thelarge-span rectangular spatially warped truss is reduced, assemblyaccuracy and speed are greatly improved, and construction materials aresaved.

There is a need in the art for automated systems and methods for lumberanalysis, sorting, adjustment, and sawing for workpiece assembly, suchas the assembly of wooden roof trusses, pre-assembled walls, and thelike.

SUMMARY OF THE INVENTION

In some embodiments, the present invention provides a method andassociated system that includes a computer processor, wherein thecomputer processor includes: a plurality of input data devices, aplurality of output data devices, and a plurality of sensors, andwherein the system further includes a mechanical assembly integratedwith the computer processor to analyze the geometry of a piece of woodor lumber and, if necessary, reposition the piece and convey the pieceto a saw or to a reject station, based on software code executing in thecomputer processor. Some embodiments organize each incoming stack oflumber in one of a plurality of vertically spaced apart bunks, one ontop of another, and provide a gantry that picks a selected board fromthe stack of lumber on a selected bunk, and moves to board in adirection generally parallel to the long axis of the board from the bunkto one of a plurality of processing stations, wherein the plurality ofprocessing stations includes a flipping station and/or a sawing station.Organizing the lumber bunks in vertical assemblies greatly reduces thefootprint of the overall system, thus making more efficient use ofvaluable factory space and reducing costs. Using the present invention,one can buy lower-grade lumber and sort the boards to obtain suitableand usable pieces for a given end product, thus reducing cost andimproving quality of the end product.

In some embodiments, the present invention provides a system andassociated method that operates on a computer processor having aplurality of input data devices, a plurality of output data devices, aplurality of sensors, a database, software code, and a wirelessinterface, wherein the computer processor is integrated with mechanicalcomponents, and wherein the method includes eliciting and receiving intothe computer processor data parameters from a first human user;obtaining incoming data points about lumber from the plurality ofsensors (e.g., in some embodiments, from optical point distance sensorsand/or three-dimensional (3D) machine-vision systems); processing thedata parameters to obtain processed data parameters; storing theprocessed data parameters; comparing the incoming data points from theplurality of sensors to the stored data parameters to obtain comparisonresults; and, based on the comparison results, (1) directing themechanical components to reject the wood to a preprogrammed position,(2) directing the mechanical components to feed the lumber into a sawassembly as positioned, or (3) directing the mechanical components toreposition the lumber to a more optimal position prior to feeding thelumber to a saw assembly.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a flowchart 101 of one embodiment of the system dataprocessing and software integration of the present invention.

FIG. 2A is a schematic diagram 201 showing exemplary data points used todetect crook in a piece of lumber 99, according to some embodiments ofthe present invention.

FIG. 2B is a schematic diagram 202 showing exemplary data points used todetect bow in a piece of lumber 99, according to some embodiments of thepresent invention.

FIG. 2C is a schematic diagram 203 showing exemplary data points used todetect twist in a piece of lumber 99, according to some embodiments ofthe present invention.

FIG. 2D is a schematic diagram 204 showing exemplary data points used todetect wane 240 and cracks 241 in a piece of lumber 99, according tosome embodiments of the present invention.

FIG. 2E is a schematic diagram 205 showing exemplary data points used todetect a knot 250 in a piece of lumber 99, according to some embodimentsof the present invention.

FIG. 2F is a schematic diagram 206 showing exemplary data points used todetect cupping 251 in a piece of lumber 99, according to someembodiments of the present invention.

FIG. 3A is a side-view schematic diagram of a lumber-analyzer system301, according to some embodiments of the present invention.

FIG. 3B is an end-view schematic diagram of lumber-analyzer system 301,according to some embodiments of the present invention.

FIG. 4A is a perspective view of a lumber-analyzer system 401, accordingto some embodiments of the present invention.

FIG. 4B is a side-view of lumber-analyzer system 401, according to someembodiments of the present invention.

FIG. 4C is a front-end view of lumber-analyzer system 401, according tosome embodiments of the present invention.

FIG. 4D is a back-end view of lumber-analyzer system 401, according tosome embodiments of the present invention.

FIG. 4E is a close-up side-view schematic diagram of a lumber-analyzersystem 401, according to some embodiments of the present invention.

FIG. 5A is a schematic diagram of a lumber-analyzer system 501,according to some embodiments of the present invention.

FIG. 5B is a schematic diagram of a lumber-analyzer system 502,according to some embodiments of the present invention.

FIG. 6 is a flowchart of a method 601, according to some embodiments ofthe present invention.

COPYRIGHT NOTICE/PERMISSION

A portion of the disclosure of this patent document contains materialwhich is subject to copyright protection. The copyright owner has noobjection to the facsimile reproduction by anyone of the patent documentor the patent disclosure, as it appears in the Patent and TrademarkOffice patent files or records, but otherwise reserves all copyrightrights whatsoever. The following notice applies to the software and dataas described herein and in the drawings hereto in the attachedappendices: Copyright © 2014-2017, Steven R. Weinschenk, All RightsReserved.

DETAILED DESCRIPTION OF THE INVENTION

Although the following detailed description contains many specifics forthe purpose of illustration, a person of ordinary skill in the art willappreciate that many variations and alterations to the following detailsare within the scope of the invention. Specific examples are used toillustrate particular embodiments; however, the invention described inthe claims is not intended to be limited to only these examples, butrather includes the full scope of the attached claims. Accordingly, thefollowing preferred embodiments of the invention are set forth withoutany loss of generality to, and without imposing limitations upon theclaimed invention. Further, in the following detailed description of thepreferred embodiments, reference is made to the accompanying drawingsthat form a part hereof, and in which are shown by way of illustrationspecific embodiments in which the invention may be practiced. It isunderstood that other embodiments may be utilized and structural changesmay be made without departing from the scope of the present invention.

It is specifically contemplated that the present invention includesembodiments having combinations and subcombinations of the variousembodiments and features that are individually described herein (i.e.,rather than listing every combinatorial of the elements, thisspecification includes descriptions of representative embodiments andcontemplates embodiments that include some of the features from oneembodiment combined with some of the features of another embodiment,including embodiments that include some of the features from oneembodiment combined with some of the features of embodiments describedin the patents and application publications incorporated by reference inthe present application). Further, some embodiments include fewer thanall the components described as part of any one of the embodimentsdescribed herein.

The leading digit(s) of reference numbers appearing in the Figuresgenerally corresponds to the Figure number in which that component isfirst introduced, such that the same reference number is used throughoutto refer to an identical component which appears in multiple Figures.Signals and connections may be referred to by the same reference numberor label, and the actual meaning will be clear from its use in thecontext of the description.

Certain marks referenced herein may be common-law or registeredtrademarks of third parties affiliated or unaffiliated with theapplicant or the assignee. Use of these marks is for providing anenabling disclosure by way of example and shall not be construed tolimit the scope of the claimed subject matter to material associatedwith such marks.

As used herein, “crook” is a lumber feature or defect where the widestfaces of the piece of lumber are substantially planar but there is acurvature along the length of the narrower faces of the piece of lumber.The “crown” is the convex one of the narrower faces of the piece oflumber with a crook. See FIG. 2A.

As used herein, “bow” is a lumber feature or defect where the narrowerfaces of the piece of lumber are substantially planar but there is acurvature along the length of the wider faces of the piece of lumber.See FIG. 2B.

As used herein, “twist” is a lumber feature or defect in which there arecurvatures across multiple surfaces in the lumber. See FIG. 2C.

As used herein, “wane” is a lumber feature or defect that ischaracterized by bark or insufficient wood at a corner or along an edge,due to the piece of lumber being cut from an outer edge of the log. SeeFIG. 2D.

As used herein, “knot” is a lumber feature or defect that ischaracterized by a separated branch piece or hole in a piece of lumber.See FIG. 2E.

As used herein, “cup” is a lumber feature or defect where there is acurvature across the width of the widest face of the lumber, in whichthe edges are higher or lower than the center of the piece of lumber.See FIG. 2F.

In some embodiments, the present invention provides a crown-detectionsystem for wood truss lumber infeed saw equipment for enhancedstructural support and safety features. In some embodiments, the presentinvention provides an automated “AutoCurvature System” that detects thecrown orientation of the lumber. In some embodiments, after detection bythe AutoCurvature System that determines the bow, crown, or twist of apiece of lumber, the AutoCurvature System automatically rejects the woodpiece, or the wood piece is reoriented.

In some embodiments, the AutoCurvature System elicits information fromthe environment or a human operator. In some embodiments, upon receiptof the initial data points, the AutoCurvature System sensors detect thecurvature of the lumber piece, and compare the parameters from thedetection to an acceptable range of data points pre-programmed in theAutoCurvature System (in some such embodiments, the comparison isperformed using an algorithm).

In some embodiments, the AutoCurvature System of the present inventiondetermines: (1) that the lumber should be rejected, (2) that thedirection of the lumber needs to be changed, or (3) that the lumbershould be fed, as situated/oriented, into the saw.

In some embodiments, the sensors of the present invention include aplurality of single-point distance-detecting optical systems. In someembodiments, the sensors also or alternatively include multiple-pointoptical systems (e.g., in some embodiments, the present inventionincludes one or more three-dimensional (3D) O3D302 sensors from IFMEfector, Inc., 1100 Atwater Drive, Malvern, Pa. 19355). In someembodiments, the sensors include mechanically driven electrical sensors.In some embodiments, the sensors include monochromatic-camera orcolor-camera technologies. In some embodiments, the sensors includelaser distance detectors. In some embodiments, the sensors includemotion detection. In some embodiments, the sensors include temperaturedetection. In some embodiments, the sensors include weight detection. Insome embodiments, the sensors include moisture detection.

FIG. 1 is a flowchart 101 of one embodiment of the system dataprocessing and software integration of the present invention. In someembodiments, at block 105, the system (e.g., system 301 of FIG. 3)elicits acceptable lumber data from a user 90 and/or from a stored setof data 130 that correlates characteristics of lumber with certainactions to be taken by the system, based on the end product to be builtusing the pieces of lumber. In some embodiments, system 301, usingmethod 101, elicits and receives, from a human user 90 using aninput/output device 120, selection data that the system uses to selectsone or more sets of criteria and corresponding actions from a storeddatabase that has been pre-loaded with a plurality of sets of criteriaand corresponding actions that have been predetermined to meetrequirements for each of a plurality of possible end products to bebuilt using the pieces of lumber. In some embodiments, the presentinvention utilizes one or more of the user devices 120 of each user 90,such as a desktop personal computer 121, laptop computer 122, tabletcomputer 123, smartphone 124, a position-sensing device 125 (which insome embodiments, is a stand-alone Global Positioning System (GPS)device (such as made by Garmin Ltd.) or in other embodiments, is part ofa position-tracking system or another device such as a smartphone 124 orthe like), and/or other devices such as wearable computers in clothingor smartwatches 127 or the like. In some embodiments, the human user 90responds to the eliciting of information by indicating to system 301which one of a plurality possible end-products is to be manufactured,wherein the criteria and actions for each respective end product iscustomized and optimized for that respective end product and stored indatabase 130, such that when an indication is received from the device120 of user 90, that set of data is then used for the operations ofblocks 106 through 112. In some embodiments, at block 106, sensorsgather physical data from lumber. In some embodiments, distance data isreceived from each of one or more sensors for each of a plurality ofpoint locations on one or more pieces of lumber. In some embodiments,those distance data are processed to obtain XYZ coordinates for each ofthe plurality of point locations, and curve-fitting algorithms areapplied to find edges and surfaces of the one or more pieces of lumber,and determine the shapes and curves of edges and surfaces of the lumber.In some embodiments, at block 107, the physical geometric data iscompared to the selected set of lumber parameters to obtain datacomparison results. In some embodiments, at block 108, the datacomparison results have been determined to be acceptable and thereforethe piece of lumber is delivered to the processing equipment for the endproduct being manufactured (such as, for example, an automated saw). Insome embodiments, at block 109, the data comparison results have beendetermined to be unacceptable and un-fixable (at least in regards tothis particular station and the uses to which the lumber is to beapplied in a commercially reasonable fashion), so control is passed toblock 111, and the piece of lumber is delivered to the rejection area.In some embodiments, at block 110, the piece of lumber is determined tobe processable if reoriented, so that piece should be reoriented, so asa result the lumber is delivered to a reorienter. In some embodiments,at box 112, the orientation of the lumber is changed by the reorienterand then the now-reoriented piece of lumber is delivered to theprocessing equipment for the end product being manufactured (such as theautomated saw).

FIG. 2A is a schematic diagram 201 showing a top view of a plurality ofexemplary data points 291 gathered along the length of a board and usedto detect crook in a piece of lumber 99, and if crook is detected, usedto determine the crown face 91 and the amount of curve on the crown face91, according to some embodiments of the present invention.

FIG. 2B is a schematic diagram 202 showing a side view of a plurality ofexemplary data points 292 gathered along the length of a board and usedto detect bow in a piece of lumber 99, and if bow is detected, used todetermine the amount and direction of curve on the bowed face 92,according to some embodiments of the present invention.

FIG. 2C is a schematic diagram 203 showing a side view of a plurality ofexemplary data points 293 gathered along the length of a board and usedto detect twist in a piece of lumber 99, and if twist is detected, usedto determine the amount and direction of curve on the twisted face 93,according to some embodiments of the present invention.

FIG. 2D is a schematic diagram 204 showing a perspective view of aplurality of exemplary data points 294 gathered across the width of aboard and used to detect cracks 241 and wane 240 in a piece of lumber99, and if cracks and/or wane are detected, used to determine the amountand position of any crack(s) and/or the amount and which corner(s) aremissing on the wane surface 94, according to some embodiments of thepresent invention.

FIG. 2E is a schematic diagram 205 showing a perspective view of aplurality of exemplary data points 295 gathered across the width of aboard and used to detect a knot 250 in a piece of lumber 99, and if oneor more knots are detected, used to determine the size and position ofany knots and/or the amount (size) and positions of the missing wood atthe knot position 95, according to some embodiments of the presentinvention. In some embodiments, one or more of the data points (e.g.,point 295′) indicates a data point in the middle of a board that is wellbelow the other data points 295 on the top surface.

FIG. 2F is a schematic diagram 206 showing a perspective view of aplurality of exemplary data points 296 gathered across the width of aboard and used to detect cupping 251 in a piece of lumber 99, and ifcupping is detected, used to determine the amount and direction ofcurve/cupping on the cupped face 96, according to some embodiments ofthe present invention.

FIG. 3A is a side-view schematic diagram of a lumber-analyzer system301, according to some embodiments of the present invention. In someembodiments, system 301 includes a computer processor 305 (in someembodiments, a Raspberry Pi® is used for processor 305 and is located ongantry 308, and uses open-source software (e.g., OPENCV) that has box,line, and color detection as well as knot and crack detection, wheresometimes wane shows better in images from a visual sensor due to thecolor of bark), wherein computer processor 305 includes a plurality ofinput/output data devices 306 and a plurality of gantry sensors 307 thatobtain image and/or distance data 377 from the top of lumber 99 on cart320, and/or bottom-side sensors 307′ that obtain image and/or distancedata 377′ from the bottom of a piece of lumber 99 that has been removedfrom a cart 320 (e.g., in some embodiments, one of a plurality of suchcarts 320-321) as the piece of lumber is being moved toward therejection station 370, the flip station 380 and/or the saw station 390(see FIG. 3B). In some embodiments, system 301 further includes amechanical assembly 308 integrated with computer processor 305 to grab(using picker assembly 325) and reposition a piece of wood lumber 99based on software code executing in computer processor 305 thatprocesses the point location data received from gantry sensors 307and/or bottom-side sensors 307′. In some embodiments, a database 130(containing criteria-and-action data for each one of a plurality of endproducts to be made from the lumber) is operatively coupled to computerprocessor 305. In some embodiments, a non-transitory computer-readablemedium 310 (storing thereon instructions for performing the method ofthe present invention) is connectable to computer processor 305, forexample, via one or more of the plurality of input/output data devices306.

FIG. 3B is an end-view schematic diagram of lumber-analyzer system 301,according to some embodiments of the present invention, which, forconvenience, illustrates the processing of lumber where the lumber ismoved left-to-right in the figure. In some embodiments, only top-sidegantry-located sensors 307 are used, while in other embodiments, onlybottom-side sensors 307′ are used, while in yet other embodiments, bothtop-side gantry sensors 307 and bottom-side sensors 307′ are used. Insome embodiments, the mechanical assembly (e.g., the gantry) 308 has (inaddition to the gantry sensors 307 if used) a single board-pickermechanism 325 that is used and carries one board at a time (fromleft-to-right in the FIG. 3B), while in other embodiments, gantry 308has (in addition to the gantry sensors 307 if used) a plurality ofboard-picker mechanisms 324-325 that are each used to carry one or moreboards at a time (from left-to-right in the FIG. 3B). In someembodiments, gantry 308 is operable to pick one or more boards from eachof one or more of a plurality of carts 320-321 (only two of which areshown here).

Continuing to refer to FIG. 3B, in some embodiments that use onlytop-side gantry-located sensors 307, a board 99 is scanned or imaged bygantry sensors 307 to determine the position and orientation of board 99in absolute terms and/or in relation to other boards 97 and 98. In someembodiments, the points along the edges and top surface of board 99 aredetermined and distinguished by the height difference relative to thepoints detected of a lower board 97. In some embodiments, the pointsalong the edges and top surface of board 99 are determined anddistinguished by the brightness differences of the boards relative tothe spaces between top board 99 and top board 98. In some embodiments,the points along the edges and top surface of board 99 obtained fromtop-side gantry-located sensors 307 are used to position picker(s) 324and/or 325 in order to pick up board 99 (and/or simultaneously pick upboard 98). Based on the geometry data obtained from the top-sidegantry-located sensors 307, the board 99 is picked up by path 371,carried along path 372, possibly dropped along path 379 to rejectionstation 370 (in the case where system 301 and method 101 have determinedthat the current processing stations are not able to accommodate thedetected flaws in the board), or deposited on flip station 380 by path373 and/or taken to saw station 390 by path 375. In some embodiments, ifthe board is deposited on flip station 380, it is flipped over alongpath 374 (rotated 180 degrees around its long axis) and then theopposite side is inspected by gantry sensors 307 (or the board is pickedup by picker(s) 324-325 and transported back over the bottom-sidesensors 307′ to perform the detailed inspection of the side notoriginally inspected during the first pass over sensors 307′), and basedon the inspection of the opposite side, the now doubly-inspected boardis dumped at reject station 370 or transported and placed on saw station390.

In some embodiments, system 301 uses its detection of the crown face(which typically has only one “high” point) of a crooked board to placethe side opposite the crown face (which typically has two “high” points)against the saw fence of saw station 390 so the board is more stable anddoes not move as the board is being sawed. Flip station 380 facilitatesthis positioning.

In some embodiments, system 301 uses method 101 to elicit and receiveoptical and/or XYZ point locations data (geometry data regarding thesurfaces and edges of the lumber) to detect and measure wane or crackson the board (see FIG. 2D). In some embodiments, system 301 detects cupdefects (see FIG. 2F). In some embodiments, the system 301 detects crookdefects (see FIG. 2A) and determines the crown face of the board. Insome embodiments, system 301 further performs wane detection and/orsplit detection (see FIG. 2D), knot detection (see FIG. 2E), and/or barkdetection (see FIG. 2D).

In some embodiments, system 301 detects other data (non-geometry data)such as grain quality and ring density. In some embodiments, theseparameters are determined by one or more video cameras and one or moremachine-vision algorithms applied to images obtained from the camera(s).

In some embodiments, system 301 reorients the lumber by physicallyflipping the lumber piece around its longest axes and/or rotating thelumber piece on one of its short axes to better optimize wood viamechanical action. In some embodiments, reorientation of the lumber isaccomplished using compressed air; for example, by placing the piece oflumber on a surface (of flip station 380) having a plurality of holesthrough which compressed air is selectively applied in a short burstalong one edge to flip the board around its longest axis. In some otherembodiments, reorientation of the lumber uses mechanical clamps orfasteners, such as a clamping device that grabs opposite faces of thepiece of lumber, or a piercing device that screws or pierces to grab thelumber and flip the board around its longest axis.

FIG. 4A is a perspective view of a lumber-analyzer and processing system401, according to some embodiments of the present invention. In someembodiments, system 401 includes a plurality of lumber-carrying carts320-321 (ten such carts are shown here), and gantry 308 conveys one ormore pieces of lumber 98-99 from one of the carts 320-321 eventually tosaw station 390 in the upper left of the diagram of FIG. 4A. In someembodiments, gantry 308 travels along track 411 that is supported by aplurality of cantilevered arms 410, and which runs at right-angles totrack 411. In some embodiments, bottom-side sensors 307′, as well asstations 370 and 380 of FIG. 3B (not shown here for simplicity) arelocated between end cart 321 and saw station 390. In other embodiments,bottom-side sensors 307′, and stations 370 and 380 of FIG. 3B arelocated at other suitable positions. In some embodiments, anotherconveyor system using track 491 and gantry 498 picks up and moves thesawn lumber pieces from saw station 390 to a truss-assembly station 490(for example, such as described in U.S. Provisional Patent Application62/144,859 by Steven Weinschenk, and U.S. patent application Ser. No.15/093,732 filed Apr. 7, 2016 by Steven R. Weinschenk et al., titled“DIGITAL PROJECTION SYSTEM AND METHOD FOR WORKPIECE ASSEMBLY”; and/orthe other patents and patent publications described in the backgroundsection above, which are incorporated herein by reference in theirentirety).

In some embodiments, one or more human users 90 communicate with system301 or 401 via wireless communications such as one or more of thedevices 110 of FIG. 1. In some such embodiments, human users 90communicate with system 301 or 401 via wireless mobile devices 123, 124,125 and/or 127.

FIG. 4B is a side-view of system 401, according to some embodiments ofthe present invention. The various parts and features are as describedabove for like reference numbers. In some embodiments, the gantrysensors 307 are mounted on sensor arm 405. In some embodiments, the carthandles 329 are located on the opposite end of cart 320 as shown inFIGS. 4A and 4B, such that human workers can pull empty carts outtowards the left and replace the removed empty carts with carts full oflumber pieces by pushing the replacement carts into position in aleft-to-right direction relative to this figure.

FIG. 4C is a front-end view of system 401, according to some embodimentsof the present invention. The various parts and features are asdescribed above for like reference numbers.

FIG. 4D is a back-end view of system 401, according to some embodimentsof the present invention. Again, the various parts and features are asdescribed above for like reference numbers.

FIG. 4E is a close-up side-view schematic diagram of a portion of system401, according to some embodiments of the present invention. In someembodiments, system 401 uses gantry sensors 307 that include a pluralityof distance sensors 450 mounted to arm 405 at a plurality ofspaced-apart locations and angled orientations situated to sense bothends and a plurality of intermediate positions of boards up to about 20feet (about 6 meters) long. In some embodiments, five point sensors areused, and the system is calibrated to convert the distance parameterfrom each sensor (which is at a given angle and sensor height, and aknown Z-position of the gantry 308 along track 411) to the X, Y, and Zcoordinates of each point measured. In other embodiments, a 3D sensor(e.g., the O3D302 sensor from IFM Efector, Inc., 1100 Atwater Drive,Malvern, Pa. 19355) measures XYZ coordinates of a plurality of locationssubstantially simultaneously (e.g., up to 64 or more points at each timea measurement is taken (e.g., in some embodiments, up to four or moretimes per second)). In some embodiments, track 411 is mounted on arm460, and motor 461 moves one or more pickers 324-325 up and down, whilemotor 462 is used to move gantry 308 and sensors 307 together alongtrack 411 (in a direction that would be towards or away from the surfaceof FIG. 4E). In some embodiments, picker 324 includes a plurality ofsuction (vacuum) operated attachment units 326, and picker 325 includesa plurality of suction (vacuum) operated attachment units 327. In otherembodiments, other picker modalities are used (such as piercing pointsor screws that penetrate the piece of lumber, or clamping jaws that graband hold the lumber).

FIG. 5A is a schematic diagram of a lumber-analyzer and processingsystem 501, according to some embodiments of the present invention. Insome embodiments, system 501 includes a gantry 308 that moves in and outrelative to a plurality of stacks of lumber, each located on one of aplurality of bunks 528 (in the embodiment shown here, each bunk uses ashelf 529 to support its stack of lumber; in other embodiments, aplurality of cantilevered arms extending perpendicular to the long axesof the boards are spaced apart along the length of the boards andfacilitate loading the bunks using a forklift or similar machinery) thatare vertically displaced relative to one another, in contrast to stacksof lumber that are horizontally displaced relative to one another asshown in FIGS. 4A-4E. In some such embodiments, the picker 324 movesleft-and-right relative to the figure to reach in above a selected oneof the plurality of stacks of lumber 520-521, where one or more stacksof lumber 520-521 are placed on a plurality of vertically displacedshelves 529. A Y-track 537 is used to move the gantry 308 vertically toa selected one of the plurality of shelves 529 and its stack(s) oflumber 520-521, where a picker 324 (e.g., in some embodiments, usingsuction grippers) picks up a board that has been measured (as describedabove, for crook, bow, twist, cup, cracks and/or knots and the like),and delivered to flipper 380 and/or saw 390, or to the reject station370. Thus, in some embodiments, gantry 308 moves up-down to one ofplurality of stacked bunks (using shelves 529 or other suitablesupports) of lumber stacks 320-321. Gantry 308 moves left-right overselected stack (e.g., 321) of lumber, picks a selected board 99, andcamera/scanner 307 measures crown, bow, twist, wane, color, grade.Gantry 308 moves back-forth using tracks 538 and 539 between the stackedbunks 528 and saw input table of saw unit 390 (or flipper 280 or thediscard pile of the reject unit 370).

FIG. 5B is a schematic diagram of a lumber-analyzer system 502,according to some embodiments of the present invention. In someembodiments, system 502 is similar to system 501 described above, buthas sets of bunks of lumber that are vertically displaced on both of thetwo sides of a centrally positioned gantry-movement system. Thus, insome embodiments, gantry 308 moves up-down to one of plurality ofstacked bunks (using shelves 529 or other suitable supports) of lumberstacks 320-321. Gantry 308 moves left-right over selected stack (e.g.,321) of lumber, on the LEFT SIDE OR RIGHT SIDE of the centralgantry-movement system 520, and picks a selected board 99, andcamera/scanner 307 measures crown, bow, twist, wane, color, grade.Gantry 302 moves back-forth using tracks 538 and 539 between the twosets of stacked bunks and saw input table of saw unit 390 (or flipper280 or the discard pile of the reject unit 370).

FIG. 6 is a flowchart of a method 601, according to some embodiments ofthe present invention. In some embodiments, method 601 includes block610 that establishes the angle each sensor is sampling and the distancesto the sample horizontal plane board (this angle is used to establishthe height vertically from the ground); block 612 that moves the sensorsmounted on the gantry over the board piles using an encoded positioningmovement; block 614 that records distances linearly along the x axis(the long dimension of the board), with compensation for the sensorangle to board applied (to change from a linear distance at angle to XYZcoordinates of each point measured), recorded as Z axis distance to thefloor, X axis along length of board and Y axis across width of board;block 616 that evaluates the data to find the change in height from onelevel of boards to the next level of the top two levels on a stack ofboards (in order to distinguish where the edge of the board is—thetransition from one plane to the next indicates the edge of the board atfive or more locations, which determines whether the board is straightor curved); block 618 that evaluates these positions using a lineformula in the Y axis to see how straight is the line along the X axisand if it falls outside the specified straightness for an acceptableboard; block 620 that, if the straightness is outside the specifiedlimits, then attempts an additional flipping procedure to the processingof the board (to ensure that the proper edge (e.g., the outside or crownedge) is on the desired side of the board); and block 622 thatoptionally evaluates the data to determine if the board is acceptable ina bow or twist shape by evaluation of the x and/or z data in a lineformula. In some embodiments, the present invention provides a vacuumpicker, a screw picker, a hook picker, a clamp picker, a piercingpicker, or a picker that incorporates a plurality of such modalities. Insome embodiments, a dual picker includes two sets of vacuum pick heads,each set able to pick a separate board. In some embodiments, if twist orcupping is detected, the system may reject board. In some embodiments,wane boards are lower grade and the system can pick through the boardsand sort relative to criteria that indicates “OK for some uses.” In someembodiments, the sensors 307 are all on the top-of gantry. In someembodiments, another set of sensors 307′ is looking up to detect wane,bow, etc. from underneath. In some embodiments, sensors 307′ are analternative to top-side sensors 307 or in other embodiments, they are anadditional set of sensors. When used, sensors 307′ scan the underneathside of boards on the picker 325. In some embodiments, the boards areput on flipping station 380 before re-grabbing to put onto saw station390.

In some embodiments, the home position for each of the plurality ofcarts 320-321 includes a centering track and an end stop thatfacilitates locating of the cart so the system 301 can more easilylocate the cart and its stack of lumber.

In some embodiments, the present invention provides a method and systemthat performs one or more of the following procedures:

-   -   scans or images a pile of lumber;    -   determines whether one or more boards is acceptable as is or if        it/they need reorientation;    -   orients the board such that the crown of this board matches (is        oriented in the same direction as the crown of another board in        the truss or wall section being assembled) or complements (is        oriented to compensate for the crown of another board that is        oriented in a different direction) another board;    -   detects the dimension (whether 2×4, 2×6, 2×8, or other        dimension) of a selected board (which is particularly useful if        boards of different dimensions are mixed in a pile held by a        cart or bunk, or when several piles are available and someone        changes carts or the operator does not want to enter the data by        hand for each cart), wherein in some embodiments, the system        detects indents between boards in an image and measures the        width of each board;    -   measures how high a stack of 2×4's is and uses the height and        width to determine how many pieces of lumber are in the pile;        and/or    -   determines whether there are enough lumber pieces for the        current job.

For example, in some embodiments, if there are ten carts in a row (eachcart holding a plurality of pieces of lumber), the machine goes to acart and re-scans the cart (in case a person has moved the cart, oradded or removed boards, or some other change has occurred), picks up aboard and delivers the board to the saw machine or to the flippermachine.

In some embodiments, the measurement and determination of the geometry(curves, bow, crown direction and the like) is performed while the boardis on a cart 320 or bunk 528, and/or held by a picker on the gantry 308,and/or on the flipper station 380.

In some embodiments, the sensors include multiple single-point distancesensors (e.g., analog distance sensors such as a modelVDM28-8-L-IO/110/115b/122 distance sensor available from Pepperl andFuchs; www.pepperl-fuchs.com), which provide outputs wherein a perfectlystraight board trips all the sensors at the same time. Sometimes, if aboard is diagonal (for example, as a result of a person hand throwinglumber in pile), then the vacuum pickups cannot pick up the board. Assensors go over the board, the sensors trip in sequence (at differenttimes) so board is determined to be straight but skewed on the pile. Inother embodiments, instead of analog sensors, the system 301 or 401 usesa video camera and filters the image data to find the data needed (forexample, the color of the lumber can tell whether each board is treated(e.g., with anti-rot chemicals) or not treated) and tells length (insome embodiments, the method and system use OPENCV open-source softwareto analyze the images). In some embodiments, the user will retrofit themachine by adding a camera, then archive (store into an image database)the images of each board that go in, so that when a particular boardgoes into a truss as the truss is being manufactured, the forensicinvestigator can tell when that board got cracked (before, during orafter assembly). Some embodiments further include one or moreKinect®-type 3D sensor-and-camera subsystems. Such scanners may costonly about $2000, and the scanner can get a 3D profile to measure howmuch wane is missing on a board (for example, if the wane is only onthree feet of a 20 foot-board, the system can cut pieces to maximize thevalue obtained from pieces of that board, thus obtaining much greatervalue than the cost of the 3D sensor).

In some embodiments, the system 301 or 401 includes an image projectorthat projects an image onto the work surface of saw machine 390 (similarto projection systems such as described in co-pending U.S. patentapplication Ser. No. 15/093,732 filed Apr. 7, 2016 by Steven R.Weinschenk et al., titled “DIGITAL PROJECTION SYSTEM AND METHOD FORWORKPIECE ASSEMBLY”; which is incorporated herein by reference in itsentirety), then notifies the human operator to reposition a board on thesaw machine work surface according to the projected image. This isparticularly useful for unusual situations where the system hasdifficulty correcting for a particular defect in a board (by moving theboard on the saw so it can be properly cut).

In some embodiments, system 301 or 401 uses one of the sensors 307 toscan reloaded carts for barcodes on the lumber or other indicia such asa barcode on wrapping paper. The scanned barcode information goes intogantry system and is communicated to the system processor. In someembodiments, a smartphone scan by the operator is wirelesslycommunicated into gantry system to collect barcode from carts andbarcodes from lumber wrapper, and correlate the barcode from the wrapperto the barcoded cart holding lumber previously in that wrapper. In someembodiments, for a grade stamp that is only on a board, or alternativelyon the wrapper, in text, the system 301 or 401 reads those charactersand performs OCR (optical character recognition) to get grade of everyboard. In some embodiments, system 301 or 401 flips a piece of lumber toget an image of the grade stamp on that board.

In some embodiments, system 301 determines the length of each board,which is needed because operators sometimes throw boards on pile bymistake.

In some embodiments, system 301 or 401 includes a projector system (suchas SteadyShot™, or such as described in co-pending U.S. patentapplication Ser. No. 15/093,732 filed Apr. 7, 2016 by Steven R.Weinschenk et al., titled “DIGITAL PROJECTION SYSTEM AND METHOD FORWORKPIECE ASSEMBLY” which is incorporated herein by reference in itsentirety) that is originally used for roof trusses, but in the presentsystem is now also used for wall panels, studs, windows, cripple studsand the like. In some embodiments, the system then takes a picture ofwall before putting sheeting on it when building a wall section.Conventional systems and methods using a power nailer assumed studs werestraight (not bowed) so nails would miss the bowed studs. To remedythis, some embodiments of the present system take a digital image of theassembled stud product before sheathing is applied, and then use aprojector system to project, onto the sheathing, the image of the studstaken before the sheathing is placed over the studs (so the humanoperator of the nailing gun can see exactly where the underlying studsare when nailing) and/or the predetermined nailing pattern for aparticular wall panel, as automatically modified by pattern-recognitionsoftware based on the image of the studs taken before the sheathing isplaced over the studs, where the projected image of the studs showsbowed studs that are hidden behind sheeting, providing a way for theuser to nail into the bowed studs.

In conventional systems, the stacks are limited-whole job must be samegrade. In contrast, system 301, 401 or 501 can pick and choose boardsfrom a pile containing different lengths and grades of lumber and selectboards that are best suited and modifiable to optimize the product beingbuilt.

In system 301 or 401, the gantry 308 works with horizontal boards thatare piled on side-by-side carts 320-321. The horizontal spacing of thecarts 320 takes lots of floor space. A factory often needs to pullequipment and other items out to put in a conventional cart-basedsystem. In contrast, the new vertical picker of system 501 allows thepicker and gantry to pick off boards from stacks that are on top of oneanother on bunks (shelves or other types of lumber holders).

In some embodiments, the saw stations 390 (of system 301, 401 or 501)cut pieces from 16-foot, 18-foot, and 20-foot boards-often the productneeds a 6-foot board, and that leaves a 10-foot piece, which the systempicks up and puts back on one of the “incoming” piles of lumber on acart 320 or bunk 528.

In some embodiments, system 501 (sometimes called a vertical air pickwood runner) has a new gantry 528 that moves horizontally in a directionparallel to the long axis of boards on single shelf that has 10-foot and6-foot pieces end-to-end on the same cart 320-321 or bunk 528.

In some embodiments, system 301, 401 or 501 includes a “light-curtain”scanner to stop the machinery if people move into the way (providing avolume of space within which the machinery can move without harming aperson). In some embodiments, the gantry moves up and out of way so aforklift gains access to load wood onto a bunk 528.

In some embodiments, the present invention includes a 24-foot long “rip”saw operatively coupled to the infeed of a cross-cur saw station 390,wherein the rip saw slices a board end-to-end parallel to its long axis(e.g., to cut a 2×8 board into a 2×6 board and a 2×2 board).

In some embodiments, system 502 has a gantry 308 that picks boards frombunks on either side of the lengthwise path of the gantry motion system.

In systems that have ten bunks on carts that are horizontally spaced, ittakes lots of floor space. In some embodiments, system 502 includes aplurality of sets of bunks, wherein each set of eight bunks has its owngantry (e.g., a four-high double-sided organization). In someembodiments, system 501 or 502 includes a further set of bunks spacedlengthwise at a distance further from the saw station 390 as the setshown in FIG. 5A or FIG. 5B. In some embodiments, system 501 or 502includes a further set of bunks spaced lengthwise on the opposite end ofthe saw station 390 as the set shown in FIG. 5A or FIG. 5B.

In summary, some embodiments include: 1) Crown detection scanner andimage camera that analyze the boards from gantry 308 or a fixed table(such as flip table 380), optionally including lasers and/or scannersand/or cameras for detecting size and number of pieces and length andcolor and grade marks of the boards; 2) a bar-code scanner system thatcorrelates the original pack (the wrapped pile of lumber) and the cartto which the pile was loaded, in order that the cart bar code can beused to look up the bar code of the wrapper; 3) an OCR or other opticaltext reader that determines the grade(s) of the boards; and/or 4) avertical wood runner (such as system 501 or 502) that uses verticallystacked bunks 528.

In some embodiments, the present invention provides a system thatincludes a computer processor that includes: a plurality of input datadevices, a plurality of output data devices, and a plurality of sensors;and a mechanical assembly integrated with the computer processor toreposition a piece of wood lumber based on software code executing inthe computer processor. In some embodiments, the system further includesa database operatively coupled to the computer processor.

In some embodiments, the present invention provides a method thatoperates on a computer processor having a plurality of input datadevices, a plurality of output data devices, a plurality of sensors, adatabase, software code, and a wireless interface, wherein the computerprocessor is integrated with mechanical components, and wherein themethod includes eliciting and receiving into the computer processor dataparameters from a first human user; obtaining incoming data points aboutlumber from the plurality of sensors; processing the data parameters toobtain processed data parameters; storing the processed data parameters;comparing the incoming data points from the plurality of sensors to thestored data parameters to obtain comparison results; and conditionallydirecting the mechanical components to reject the lumber to apreprogrammed position based on the comparison results.

In some embodiments, the method further includes conditionally directingthe mechanical components to feed the lumber into a saw assembly aspositioned based on the comparison results. In some embodiments, themethod further includes conditionally directing the mechanicalcomponents to reposition the lumber to a more optimal position prior tofeeding the lumber to a saw assembly based on the comparison results.

In some embodiments, the present invention provides a non-transitorystorage medium having computer-executable instructions stored thereon,wherein the instructions, when executed on a suitable computer processorintegrated with mechanical components and having a plurality of inputdata devices, a plurality of output data devices, a plurality ofsensors, a database, software code, and a wireless interface, perform amethod that includes eliciting and receiving into the computer processordata parameters from a first human user; obtaining incoming data pointsabout lumber from the plurality of sensors; processing the dataparameters to obtain processed data parameters; storing the processeddata parameters; comparing the incoming data points from the pluralityof sensors to the stored data parameters to obtain comparison results;and conditionally directing the mechanical components to reject thelumber to a preprogrammed position based on the comparison results.

In some embodiments, the non-transitory storage medium further includesinstructions that cause the method to further include conditionallydirecting the mechanical components to feed the lumber into a sawassembly as positioned based on the comparison results. In someembodiments, the non-transitory storage medium further includesinstructions that cause the method to further include conditionallydirecting the mechanical components to reposition the lumber to a moreoptimal position prior to feeding the lumber to a saw assembly based onthe comparison results.

In some embodiments, the present invention provides a system foranalyzing and manipulating a first piece of lumber, wherein the firstpiece of lumber is one of a plurality of lumber pieces on a lumber pile,the system including: a gantry structure; a lumber picker operativelycoupled to the gantry structure; a lumber flipper; a saw unit; and alumber-analysis unit operably coupled to the lumber picker, wherein thelumber-analysis unit is configured to analyze defects in the first pieceof lumber and generate a lumber-defect result based on the analyzeddefects, wherein the lumber picker and gantry structure are configuredto move the first piece of lumber from the lumber pile to one of aplurality of destinations that includes the lumber flipper and the sawunit based on the lumber-defect result.

In some embodiments of the system, the lumber-analysis unit is furtherconfigured to determine a plurality of dimensions of the first piece oflumber.

In some embodiments of the system, the lumber-analysis unit isconfigured to analyze crook defects and to determine a crown if a boardhas a crook defect.

In some embodiments of the system, the lumber-analysis unit isconfigured to analyze twist defects, wherein the lumber-analysis unit isconfigured to analyze bow defects, wherein the lumber-analysis unit isconfigured to analyze knot defects, and wherein the lumber-analysis unitis configured to analyze wane defects.

Some embodiments of the system further include a plurality of verticallyspaced-apart lumber bunks, wherein the lumber picker and structure areoperatively coupled to pick a selected piece of lumber from a selectedone of the plurality of vertically spaced-apart lumber bunks.

Some embodiments of the system further include a sets of lumber bunks,wherein each one of the plurality of sets includes a plurality ofvertically spaced-apart lumber bunks, wherein the lumber picker andstructure are operatively coupled to pick a selected piece of lumberfrom a selected one of the plurality of vertically spaced-apart lumberbunks of a selected one of the plurality of sets.

In some embodiments of the system, the lumber-defect result isacceptable such that the lumber picker is configured to pick up thefirst piece of lumber from the lumber pile and deliver the first pieceof lumber to a saw without reorienting the first piece of lumber.

Some embodiments of the system further include a lumber flipperconfigured to reorient lumber, wherein the lumber-defect result isunacceptable such that the lumber picker is configured to pick up thefirst piece of lumber from the lumber pile and deliver the first pieceof lumber to the flipper.

In some embodiments of the system, the lumber-defect result isunacceptable such that the lumber picker is configured to pick up thefirst piece of lumber from the lumber pile and deliver the first pieceof lumber to a discard pile of lumber.

In some embodiments of the system, the lumber picker includes aplurality of suction cups configured to grasp the first piece of lumbersuch that the first piece of lumber can be lifted off of the lumber pileand transported.

In some embodiments of the system, the lumber-analysis unit includes oneor more optical sensors configured to optically scan the first piece oflumber in order to analyze defects in the first piece of lumber.

In some embodiments of the system, the lumber-analysis unit includes oneor more cameras and a processor, wherein the one or more cameras areconfigured to generate images of the first piece of lumber andelectronically transmit the images to the processor, wherein theprocessor is configured to compare the images to acceptable lumberimages.

In some embodiments, the present invention provides an automated methodfor analyzing and processing lumber that implements the system describedabove.

In some embodiments, the present invention provides an automated methodfor analyzing and processing lumber that includes: providing a firstplurality of lumber stacks, wherein each one of the first plurality oflumber stacks is vertically displaced relative to at least one other ofthe first plurality of lumber stacks; selecting a first lumber stackfrom the first plurality of lumber stacks; inspecting a first lumberpiece on the first lumber stack and generating an analysis result basedon the inspecting; picking up the first lumber piece from the firstlumber stack; and transporting the first lumber piece to a processinglocation that is chosen based on the analysis result, wherein thetransporting moves the first lumber piece in a direction that generallyparallels a longitudinal axis of the first lumber stack.

In some embodiments of the method, the analysis result identifies thefirst lumber piece as unacceptable, and wherein the transportingincludes moving the first lumber piece to a discard pile.

In some embodiments of the method, the analysis result identifies thefirst lumber piece as requiring reorientation, and wherein thetransporting includes moving the first lumber piece to a lumber flipperconfigured to reorient the first lumber piece prior to furtherprocessing of the first lumber piece.

In some embodiments of the method, the analysis result identifies thefirst lumber piece as acceptable, and wherein the transporting includesmoving the first lumber piece to a saw station.

Some embodiments of the method further include: providing a secondplurality of lumber stacks, wherein each one of the second plurality oflumber stacks is vertically displaced relative to others of the secondplurality of lumber stacks, wherein the second plurality of lumberstacks is horizontally displaced relative to the first plurality oflumber stacks, and wherein the transporting includes moving the firstlumber piece along a path that runs in between the first plurality oflumber stacks and the second plurality of lumber stacks.

In some embodiments of the method, the inspecting includes measuring aplurality of defect characteristics of the first lumber piece.

In some embodiments of the method, the inspecting includes measuring aplurality of dimensions of the first lumber piece.

Some embodiments of the method further include: providing a processoroperatively coupled to a plurality of user devices, a database, and aplurality of sensors; and eliciting and receiving acceptable lumber datafrom at least one of the plurality of user devices, wherein theinspecting includes gathering physical data of the first lumber pieceusing the plurality of sensors and storing the physical data in thedatabase, and wherein the generating of the analysis result includescomparing the physical data to the acceptable lumber data using theprocessor.

Some embodiments of the method further include: after the picking up ofthe first lumber piece from the first lumber stack, inspecting the firstlumber piece from a location below the first lumber piece.

In some embodiments of the method, the picking up of the first lumberpiece includes applying a plurality of suction grippers to the firstlumber piece.

In some embodiments, the present invention provides an apparatus forautomated analysis and processing of lumber, the apparatus including: afirst plurality of lumber bunks, wherein each one of the first pluralityof lumber bunks is vertically displaced relative to at least one otherof the first plurality of lumber bunks, and wherein each bunk isconfigured to hold a stack of lumber; means for selecting a first lumberstack from the first plurality of lumber bunks; means for inspecting afirst lumber piece on the first lumber stack and generating an analysisresult based on the inspecting; means for picking up the first lumberpiece from the first lumber stack; and means for transporting the firstlumber piece to a processing location that is chosen based on theanalysis result, wherein the means for transporting moves the firstlumber piece in a direction that parallels a longitudinal axis of thefirst lumber piece.

Some embodiments of the apparatus further include a second plurality oflumber bunks, wherein each one of the second plurality of lumber bunksis vertically displaced relative to others of the second plurality oflumber bunks, wherein the second plurality of lumber bunks ishorizontally displaced relative to the first plurality of lumber bunks,and wherein the transporting includes moving the first lumber piecealong a path that runs along the first plurality of lumber bunks and thesecond plurality of lumber bunks.

It is to be understood that the above description is intended to beillustrative, and not restrictive. Although numerous characteristics andadvantages of various embodiments as described herein have been setforth in the foregoing description, together with details of thestructure and function of various embodiments, many other embodimentsand changes to details will be apparent to those of skill in the artupon reviewing the above description. The scope of the invention shouldbe, therefore, determined with reference to the appended claims, alongwith the full scope of equivalents to which such claims are entitled. Inthe appended claims, the terms “including” and “in which” are used asthe plain-English equivalents of the respective terms “comprising” and“wherein,” respectively. Moreover, the terms “first,” “second,” and“third,” etc., are used merely as labels, and are not intended to imposenumerical requirements on their objects.

What is claimed is:
 1. A system for analyzing and manipulating a firstpiece of lumber, wherein the first piece of lumber is one of a pluralityof lumber pieces on a first lumber pile, the system comprising: a gantrystructure; a lumber picker operatively coupled to the gantry structure;a lumber flipper; a saw unit; a lumber-analysis unit operably coupled tothe lumber picker, wherein the lumber-analysis unit is configured toanalyze defects in the first piece of lumber and generate alumber-defect result based on the analyzed defects, wherein the lumberpicker and gantry structure are configured to move the first piece oflumber from the first lumber pile to one of a plurality of destinationsthat includes the lumber flipper and the saw unit based on thelumber-defect result; and a first plurality of vertically spaced-apartlumber bunks, wherein the lumber picker and gantry structure areoperatively coupled to pick the first piece of lumber from a selectedone of the first plurality of vertically spaced-apart lumber bunks,wherein the first lumber pile is in the selected one of the firstplurality of vertically spaced-apart lumber bunks.
 2. The system ofclaim 1, wherein the lumber-analysis unit is further configured todetermine a plurality of dimensions of the first piece of lumber.
 3. Thesystem of claim 1, wherein the lumber-analysis unit is configured toanalyze crook defects and to determine a crown if a board has a crookdefect.
 4. The system of claim 1, wherein the lumber-analysis unit isconfigured to analyze twist defects, wherein the lumber-analysis unit isconfigured to analyze bow defects, wherein the lumber-analysis unit isconfigured to analyze knot defects, and wherein the lumber-analysis unitis configured to analyze wane defects.
 5. The system of claim 1, furthercomprising a second plurality of vertically spaced-apart lumber bunks,wherein the lumber picker and gantry structure are operatively coupledto pick a selected piece of lumber from a selected one of the groupconsisting of the first plurality of vertically spaced-apart lumberbunks and the second plurality of vertically spaced-apart lumber bunks.6. The system of claim 1, wherein the lumber-defect result is acceptablesuch that the lumber picker is configured to pick up the first piece oflumber from the first lumber pile and deliver the first piece of lumberto a saw without reorienting the first piece of lumber.
 7. The system ofclaim 1, further comprising a lumber flipper configured to reorientlumber, wherein the lumber-defect result is unacceptable such that thelumber picker is configured to pick up the first piece of lumber fromthe first lumber pile and deliver the first piece of lumber to theflipper.
 8. The system of claim 1, wherein the lumber-defect result isunacceptable such that the lumber picker is configured to pick up thefirst piece of lumber from the first lumber pile and deliver the firstpiece of lumber to a discard pile of lumber.
 9. The system of claim 1,wherein the lumber picker includes a plurality of suction cupsconfigured to grasp the first piece of lumber such that the first pieceof lumber can be lifted off of the first lumber pile and transported.10. The system of claim 1, wherein the lumber-analysis unit includes oneor more optical sensors configured to optically scan the first piece oflumber in order to analyze defects in the first piece of lumber.
 11. Thesystem of claim 1, wherein the lumber-analysis unit includes one or morecameras and a processor, wherein the one or more cameras are configuredto generate images of the first piece of lumber and electronicallytransmit the images to the processor, wherein the processor isconfigured to compare the images to acceptable lumber images.
 12. Anautomated method for analyzing and processing lumber comprising:providing a first plurality of lumber bunks, wherein each one of thefirst plurality of lumber bunks is vertically displaced relative to atleast one other of the first plurality of lumber bunks, wherein eachbunk of the first plurality of lumber bunks is configured to hold astack of lumber; selecting a first lumber stack from the first pluralityof lumber bunks; inspecting a first lumber piece on the first lumberstack and generating an analysis result based on the inspecting; pickingup the first lumber piece from the first lumber stack; and transportingthe first lumber piece to a processing location that is chosen based onthe analysis result, wherein the transporting includes moving the firstlumber piece in a direction that parallels a longitudinal axis of thefirst lumber stack.
 13. The method of claim 12, wherein the analysisresult identifies the first lumber piece as unacceptable, and whereinthe transporting includes moving the first lumber piece to a discardpile.
 14. The method of claim 12, wherein the analysis result identifiesthe first lumber piece as requiring reorientation, and wherein thetransporting includes moving the first lumber piece to a lumber flipperconfigured to reorient the first lumber piece prior to furtherprocessing of the first lumber piece.
 15. The method of claim 12,wherein the analysis result identifies the first lumber piece asacceptable, and wherein the transporting includes moving the firstlumber piece to a saw station.
 16. The method of claim 12, furthercomprising: providing a second plurality of lumber bunks, wherein eachone of the second plurality of lumber bunks is vertically displacedrelative to at least one other of the second plurality of lumber bunks,wherein the second plurality of lumber bunks is horizontally displacedrelative to the first plurality of lumber bunks, and wherein thetransporting includes moving the first lumber piece along a path thatruns in between the first plurality of lumber bunks and the secondplurality of lumber bunks.
 17. The method of claim 12, furthercomprising: providing a processor operatively coupled to a plurality ofuser devices, a database, and a plurality of sensors; and eliciting andreceiving acceptable lumber data from at least one of the plurality ofuser devices, wherein the inspecting includes gathering physical data ofthe first lumber piece using the plurality of sensors and storing thephysical data in the database, and wherein the generating of theanalysis result includes comparing the physical data to the acceptablelumber data using the processor.
 18. An apparatus for automated analysisand processing of lumber, the apparatus comprising: a first plurality oflumber bunks, wherein each one of the first plurality of lumber bunks isvertically displaced relative to at least one other of the firstplurality of lumber bunks, and wherein each bunk of the first pluralityof lumber bunks is configured to hold a stack of lumber; means forselecting a first lumber stack from the first plurality of lumber bunks;means for inspecting a first lumber piece on the first lumber stack andgenerating an analysis result based on the inspecting; means for pickingup the first lumber piece from the first lumber stack; and means fortransporting the first lumber piece to a processing location that ischosen based on the analysis result, wherein the means for transportingmoves the first lumber piece in a direction that parallels alongitudinal axis of the first lumber piece.
 19. The apparatus of claim18, further comprising: a second plurality of lumber bunks, wherein eachone of the second plurality of lumber bunks is vertically displacedrelative to at least one other of the second plurality of lumber bunks,wherein the second plurality of lumber bunks is horizontally displacedrelative to the first plurality of lumber bunks, and wherein thetransporting includes moving the first lumber piece along a path thatruns along the first plurality of lumber bunks and the second pluralityof lumber bunks.
 20. The apparatus of claim 18, wherein the means forinspecting the first lumber piece on the first lumber stack includesmeans for determining a plurality of dimensions of the first lumberpiece.